Fiber enforced thin brick sheet and process

ABSTRACT

A fiber enforced sheet for use as a wall or floor covering which comprises of adhered thin bricks bonded to a fiber-reinforced, backing layer. Thin brick is adhered to the fiber enforced sheet. The fiber enforced backing increases strength and rigidity to the thin brick during handling, and installation permits the thin bricks to be adhered to proper specification and spacing to be cut using ordinary tile or thin brick tools.

RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 16/059,994, filed on Aug. 9, 2018 and titled FIBERENFORCED THIN BRICK SHEET AND PROCESS, which is a continuationapplication of U.S. patent application Ser. No. 15/380,733, filed onDec. 15, 2016 and titled FIBER ENFORCED THIN BRICK SHEET AND PROCESS,which is a continuation application of U.S. patent application Ser. No.13/278,815, filed on Oct. 21, 2011 and titled FIBER ENFORCED THIN BRICKSHEET AND PROCESS, each of which is incorporated herein by reference inits entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to fabricated thin brick sheets for use as wallor floor coverings and a process for manufacturing such sheets. Theinvention is a veneer, one layer of which comprises of an array of gluedor adhesive applied thin bricks.

2. The Prior Art

Thin brick has long been a highly desired backing material for walls andfloors, for interior and exterior, and the like. It is attractive,durable, waterproof, and fireproof. Thin bricks are available in a widevariety of sizes, shapes, colors, patterns, textures, and surfacefinishes. They are uniquely suited to a variety of applications rangingfrom decorative accents in the homes to complete commercial exteriorfinishes.

Thin brick per se is relatively inexpensive, being made essentially fromclay minerals fired at high temperature. Not so its installation. Theconventional construction of a thin brick wall, for example, begins withthe installation of metal lath over a vapor barrier secured sheathing.Next, a scratch coat of mortar is applied to the lath followed by anaccurately leveled mortar bed for the thin brick. Should the scratchcoat be uneven, a separate, additional leveling layer of mortar may berequired. When using adhesive brick are set one by one then groutedusing mortar applied between thin brick. Individual thin bricks must becut using special equipment and tools to fit them to spaces requiringless than a full thin brick or to fit them around fixtures and the like.

Thin brick setting is a skilled occupation, commanding high wages. Thelevel of skill required, and the time-consuming nature of conventionalthin brick installation render the process very expensive.Unfortunately, due to the high cost of thin brick installation, somebuilders have attempted installation shortcuts in a misguided effort tosave money. Improper installation techniques frequently result inexpensive repairs for the homeowner or general contractor.

Given this situation, it is not surprising to find a number of proposedsolutions to the problem in the prior art. The concept of aprefabricated thin brick sheet which would not require any thin bricksetting at the installation site has long been considered. However, thethin brick sheets previously described have all proved unsatisfactoryfor reasons such as insufficient strength, excessive weight, complexityof installation, and high labor cost. And none have met with commercialsuccess to any significant extent.

Thus, it will be appreciated that the prefabricated thin brick sheetsknown in the art prior to this disclosure all relied on a core part,commonly of steel, plastic, foam, or a relatively thick backing layer toimpart some measure of structural strength and rigidity to the sheets.These cores substantially increase the thickness of the sheets, and thisin turn necessitates special mounting hardware for installation.

SUMMARY OF THE INVENTION

The present invention comprises a thin, lightweight thin brick sheetwhich greatly simplifies and reduces the cost of installing thin brickwalls, floors, and the like. The invention further comprises a method ofmaking such a sheet and or installation.

The thin brick sheets of the invention include a plurality of thinbricks pre-assembled and mounted on a fiber enforced sheet. The spacesbetween the thin bricks are filled with grout to seal these spacesagainst moisture, etc. The term “grout” should be understood to includeboth the conventional thin, cementitious mortar used for filling jointsin masonry as well as chemicals that solidify, such as polyurethanes,room temperature vulcanizing silicones, other elastomers, plastics, andthe like. The sheets normally feature a regular pattern of substantiallyrectangular thin bricks in a side-by-side, laterally spaced rectangulararray; however, a wide variety of thin brick shapes and trim pieces arecontemplated.

The thin bricks of the invention are preferably thinner and lighter thancommon bricks. Thus, the thin bricks will generally be greater than0.125 inch thick, and less then 3 inches. The light weight of the thinbricks makes it possible for relatively large sheets of such thin bricksto be assembled and handled with comparative ease. The fiber enforcedsheet may be made of a variety of materials. The sheets themselves willnormally be flexible, but it is important that they be substantiallynon-stretchable. This quality is important because the backing andbacking sheets on each thin brick sheet co-act to render the sheet rigidenough to be readily handled and worked.

Working of the thin brick sheets for example, may include cutting ordrilling with tools such as razor knifes, table saws, and the like.After the thin bricks are adhered the sheets can then be cut betweenbricks using just a razor knife. This enables such working to be carriedout with very little breaking, chipping, or other damage to the thinbrick elements.

Applying thin brick sheets over exterior require cementitious adhesivesealing all seams and applying a roll on water barrier following allbuilding codes. When applying thin brick sheets over interior, athinset, mastic or equivalent will be required.

It will be apparent that the sheets be strong, substantiallynon-stretchable, substantially water-resistant, chemically stable, andcapable of being bonded to the thin bricks as well as to plaster, wood,cement, block, drywall sheets [gypsum board; sheetrock], etc. withconventional construction adhesives. As mentioned above, wovenfiberglass fabric is an especially preferred component of the backingsheets; however, other fabrics or reinforcing agents considered suitableinclude polyester, graphite, aramid, or carbon fibers, or anycombination thereof. Especially preferred is a fiberglass combination.

Synthetic adhesives suitable for impregnating the backing sheets includeunsaturated fiberglass, phenolic, epoxy, and silicone adhesives.

In general, the adhesives should possess the same generalcharacteristics as the backing sheets. The cured adhesive should bestrong, substantially non-stretchable, substantially impervious tomoisture, function as an adhesive to bond the back surfaces of the thinbricks to the sheet, and be capable of being bonded to common wallsurfaces and the like with conventional construction adhesives such asthin set or mastic and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 Is a cross-sectional view of fiber enforced thin brick sheets ofthe said invention.

FIG. 2 Cut thru order of fiber enforced thin brick process.

FIG. 3 Is a cross-sectional view of corner thin brick using fiberenforced thin brick sheets in the process of the said invention.

FIG. 4 View of an example layout of the corner thin brick sheets of saidinvention showing application arrangement and edges of such a sheet.

DETAILED DESCRIPTION OF THE DRAWINGS

The invention will best be understood by referring to the drawings.

FIG. 1 shows a portion of a thin brick sheet in cross section.Individual thin brick elements (5) are supported by adhesive (6) on afiber-reinforced backing layer (7). Anti-adhesive paper is used on backof thin brick sheets for separation and adhesive release (8).

FIG. 2 schematically illustrates a cut thru fabricated thin bricksheets. Thin layer of anti-adhesive paper to prevent bonding of thebacking layer adhesive (9). Reinforcing fabric (10) for the backinglayer. Adhesive at a high temperature is then impregnated or applied toeither brick or fiber-reinforced backing layer (11). Individual thinbrick elements (12).

FIG. 3 schematically illustrates corner thin brick sheets. A thin layerof anti-adhesive paper is used to prevent bonding of the backing layeradhesive that is curved in the same position as a typical thin brickcorner (13). A reinforced fabric sheet is shown that is curved in thesame position as a typical thin brick corner (14). An adhesive at a hightemperature is impregnated or applied to either a corner brick orfiber-reinforced backing layer (15). The thin corner brick positioner(16) helps in the proper spacing and alignment process.

FIG. 4 shows in detail the layout of an optional embodiment of the thinbrick sheets and corner sheets of the present invention. Corner sheetsare typically applied first (17) where bricks are placed opposite ofeach other. The thin bricks are staggered in typical brick patterns (18)and fiber-reinforced backing layer extends beyond the thin brickelements on one edge of the sheet (19), while on the opposite edge thethin brick elements overhang the fiber-reinforced backing layer by anequal distance (20). This permits abutting thin brick sheets to bejoined together in such a way that the joint between bricks are theproper space to adjacent thin brick sheets.

Additional embodiments are also disclosed. In some embodiments, thefiber enforced thin brick sheet is semi-flexible, substantiallynon-stretchable, and comprises glass filaments. The fiber enforced thinbrick sheet further comprises a thin brick layer comprising a pluralityof thin bricks bonded on their back surfaces to a backing layer.

In some embodiments, the fiber enforced thin brick sheet comprises thinbricks. The thin bricks can comprise multiple types of brick, includingclay, cast brick, wire cut, and the like. The thin bricks can be formedor cut to be thin bricks. The thin bricks are applied to a backinglayer. The backing layer is a fiber-reinforced sheet.

In some embodiments, the fiber enforced thin brick sheet comprises thinbricks. The way in which you lay individual thin bricks can vary inmultiple ways, and show a variety of patterns or bonds. Differentcombinations of brick bond examples include running bond, stack bond,English bond, and the like.

In some embodiments, the backing layer is a fiber-reinforced sheet.

In some embodiments, the adhesive is selected from the group consistingof bonding adhesive, epoxy adhesive, and silicone adhesive.

In some embodiments, the reinforcing fiber is selected from one or moremembers of the group consisting of graphite fibers, aramid fibers,carbon fibers, and fiberglass fibers. In some embodiments, the fibersare woven into a grid like fabric.

In some embodiments, the backing layer is poly fiber. In someembodiments, the backing layer is formed of spun bonded glass filaments.

In some embodiments, the fiber enforced thin brick sheets overhang onone edge while on the opposing end the thin brick overhangs the backinglayer as to interlock an adjoining sheet.

In some embodiments, an adhesive of the backing layer bonds the thinbricks of the thin brick layer to the backing layer.

In some embodiments, the thin bricks are spaced from one another and thespaces between adjacent thin bricks in the thin brick layer are filledwith mortar or grout. In some embodiments, the spaces between adjacentthin bricks in the thin brick layer are filled with a cement basematerial.

In some embodiments, the adhesive is a silicone based product.

In some embodiments, a process for producing a fiber enforced thin bricksheet comprises adhering individual thin bricks into a rectangulararray, leaving spaces of approximately ¼ inch to ¾ inch between adjacentthin bricks.

In some embodiments, a process for producing a fiber enforced thin bricksheet comprises a reinforcing fabric made of fibers selected from thegroup consisting of fiberglass fibers, graphite fibers, aramid fibers,carbon fibers, and poly fibers.

In some embodiments, a process for producing a fiber enforced thin bricksheet comprises an adhesive selected from the group consisting ofunsaturated fiberglass adhesive, phenolic adhesive, epoxy adhesive, andsilicone adhesive. In some embodiments, the adhesive is an elastomericor silicone base adhesive.

In some embodiments, a process for producing a fiber enforced thin bricksheet comprises thin brick grout. In some embodiments, the thin brickgrout is cement based. In some embodiments, the thin brick grout is sandbased.

In some embodiments, a process for producing a fiber enforced thin bricksheet comprises substantially non-stretchable fiber enforced thin bricksheet having holes ranging from 1/16 inch to 2 inches for adhesivebonding.

In some embodiments, a process for producing a fiber enforced thin bricksheet comprises a fiber enforced mesh sheet ranging from 2.5 oz to 30 ozand is designed to hold the weight of multiple thin bricks.

In some embodiments, a process of applying thin bricks comprisesaccelerating the curing of the adhesive by the application of heat. Insome embodiments, the adhesive is of high heat thus accelerating thecuring time.

In some embodiments, a continuous process for producing a fiber enforcedthin brick sheet on an endless belt, where thin bricks are applied usingan adhesive, comprises: (a) feeding a reinforcing fabric onto theendless belt; (b) passing the reinforcing fabric on the endless beltthrough an impregnating zone wherein the fabric is saturated with a highheat adhesive; (c) passing the adhesive-saturated fabric through a thinbrick application zone wherein the array of thin bricks are applied tothe adhesive-saturated fabric; (d) passing the adhesive-impregnatedfabric with thin bricks through an oven which raises the temperature ofthe adhesive to increase its curing rate and to bond the thin bricks tothe backing layer comprising of fabric reinforced glue adhesive; (e)moving the fiber enforced thin brick sheet to a cutting zone wherein thesheet is cut into sections of desired size. Optional grouting stepsinclude: (f) moving the substantially cured backing layer with bondedthin bricks through a grouting zone wherein material is deposited in thespaces between the edges of adjacent thin bricks on the sheet; (g)moving the substantially cured backing layer with bonded thin bricksthrough a cleaning zone wherein water, air, or cleaning solution isapplied.

In some embodiments, a fiber enforced sheet of thin bricks for use as awall surface or the like comprises: a flexible, substantiallynon-stretchable, backing sheet; a plurality of thin bricks bonded ontheir back surfaces to said backing sheet in a side-by-side, laterallyspaced array; and a filler grout between said thin bricks. In someembodiments, the fiber enforced backing is adhered to the brick using anadhesive.

In some embodiments, the fiber enforced sheet of thin bricks for use asa wall surface or the like further comprises a contact adhesive betweenthe backing sheet and the back surfaces of the thin bricks.

In some embodiments, the backing sheet is a fabric impregnated with asynthetic adhesive.

In some embodiments, the thin bricks are rectangular, and the sheetarray is rectangular also.

In some embodiments, a process for making an anti-adhesive paperenforced sheet comprises: non bonding the back surfaces of a pluralityof thin bricks to a substantially non-stretchable backing sheet coveringthe back surfaces of said thin bricks with a flexible sheet used forreleasing of adhesive from said sheets.

In some embodiments, a fiber enforced sheet of thin bricks for use as awall surface or the like comprises: a flexible, substantiallynon-stretchable backing sheet; a plurality of thin brick corners bondedon their back surfaces to said backing sheet in a stacked verticallyspaced array; and a filler grout between said thin bricks.

In some embodiments, a corner brick is bonded to the fiber enforcedbacking. In some embodiments, the fabric is bent at an angle to that ofthe matching brick.

In some embodiments, a process of manufacturing fiber sheets bonded tocorner brick comprises using adhesive bonders.

In some embodiments, the corner thin brick is adhered in such a way asto give ¼ inch to ¾ inch exact spacing between corner bricks.

In some embodiments, a process for producing a fiber enforced thin bricksheet on an assembly process of hand gluing individual thin bricks to afiber sheet comprises using a grid, template or stencil.

In some embodiments, a process for producing a fiber enforced cornerthin brick sheet on an assembly process of hand gluing individual thinbricks to a fiber sheet comprises using a grid, template or stencil.

In some embodiments, a process of adhering thin brick to fiber enforcedsheets comprises using an adhesive that has high elevated temperaturesthus curing quickly so as to facilitate manufacture of the thin bricksheets in a timely way.

In some embodiments, a process of adhering fiber enforced sheets to afloor or a wall comprises using an adhesive that penetrates thru saidfiber enforced sheets providing a grid like bonding pattern for grout ormortar.

In some embodiments, a process of adhering fiber enforced sheets to afloor or a wall comprises using an adhesive that penetrates thru saidfiber enforced sheets and adheres to a majority of the exposed thinbrick thus helping bond the brick to the floor or the wall.

In some embodiments, a process of adhering fiber enforced sheets to afloor or a wall comprises applying an adhesive to a wall or a floorfollowed by applying a fiber enforced sheet thus enabling the adhesiveto penetrate thru the fiber enforced sheet to help hold or cling to wallor floor surfaces.

SUMMARY

Alternatively, the sheets of the present invention may be manufacturedindividually in multiple sizes. Thin bricks are placed face down or faceup within the confines of a frame designed to hold the loose thin bricksin a rectangular array. Gaps are left between the edges of adjacent thinbricks to permit the subsequent insertion of grout as is well known inthe art.

Reinforcing fabric for the backing layer is then placed over the exposedrear surfaces of the thin brick elements in the array. A adhesive isthen applied to the fabric first or brick first, saturating it andextending through it to contact the thin bricks or sheets. As theadhesive cures it bonds the backing layer to the thin bricks. Thisprocess may be accelerated by the application of heat to raise thetemperature of the adhesive/catalyst mixture thereby increasing its curerate.

When the adhesive of the backing layer has substantially cured, thebacking layer with the thin brick elements bonded to it is inverted,exposing the front face of the thin brick elements. Grout or mortarother suitable or alike material is applied to the spaces between thethin bricks.

In use, the thin brick sheets are mounted to conventional floor or wallsurfaces using construction adhesives of the type previously mentioned.

While one specific embodiment of the invention has been disclosedherein, it should be understood that this disclosure is made by way ofillustration rather than limitation. Numerous changes may be made bythose skilled in the art, particularly with reference to the dimensions,materials and configuration disclosed herein. Changes of this naturewould not depart from the spirit of the invention or the scope of theappended claims.

1-41. (canceled)
 42. A method of installing prefabricated sheets,comprising: applying an adhesive to a wall or floor surface; applying afirst prefabricated sheet to the wall or floor surface, wherein thefirst prefabricated sheet comprises a first backing layer and a recessedportion, wherein the first backing layer comprises a grid having aplurality of holes, and wherein a first portion of the adhesivepenetrates through the plurality of holes to hold the firstprefabricated sheet to the wall or floor surface; applying a secondprefabricated sheet to the wall or floor surface, wherein the secondprefabricated sheet comprises a second backing layer and an overhangingportion, wherein the second backing layer comprises a grid having aplurality of holes, and wherein a second portion of the adhesivepenetrates through the plurality of holes to hold the secondprefabricated sheet to the wall or floor surface; joining theoverhanging portion of the second prefabricated sheet to the recessedportion of the first prefabricated sheet.
 43. The method of claim 42,wherein the first prefabricated sheet comprises a first plurality ofbricks.
 44. The method of claim 42, wherein the first backing layer isnon-stretchable.
 45. The method of claim 42, wherein the first backinglayer comprises at least one of fiberglass, polyester, graphite, aramid,or carbon.
 46. The method of claim 45, wherein the first backing layercomprises fiberglass.
 47. The method of claim 42, wherein the firstprefabricated sheet comprises a running bond pattern or a stack bondpattern.
 48. The method of claim 47, wherein the first prefabricatedsheet comprises a stack bond pattern.
 49. The method of claim 42,wherein the overhanging portion comprises a portion of the secondprefabricated sheet that overhangs the second backing layer at a firstlateral edge of the second backing layer.
 50. The method of claim 42,wherein the adhesive comprises a construction adhesive.
 51. The methodof claim 42, wherein the first backing layer comprises holes between1/16 inch and 2 inches.
 52. A method of installing prefabricated sheets,comprising: applying an adhesive to a wall or floor surface; applying afirst prefabricated sheet to the wall or floor surface, wherein thefirst prefabricated sheet comprises a first backing layer and a recessedportion, wherein the first backing layer comprises a grid having aplurality of holes, and wherein a first portion of the adhesivepenetrates through the plurality of holes; applying a secondprefabricated sheet to the wall or floor surface, wherein the secondprefabricated sheet comprises a second backing layer and an overhangingportion, wherein the second backing layer comprises a grid having aplurality of holes, and wherein a second portion of the adhesivepenetrates through the plurality of holes; joining the overhangingportion of the second prefabricated sheet to the recessed portion of thefirst prefabricated sheet.
 53. The method of claim 52, wherein the firstprefabricated sheet comprises a first plurality of bricks.
 54. Themethod of claim 52, wherein the first backing layer is non-stretchable.55. The method of claim 52, wherein the first backing layer comprises atleast one of fiberglass, polyester, graphite, aramid, or carbon.
 56. Themethod of claim 55, wherein the first backing layer comprisesfiberglass.
 57. The method of claim 52, wherein the first prefabricatedsheet comprises a running bond pattern or a stack bond pattern.
 58. Themethod of claim 57, wherein the first prefabricated sheet comprises astack bond pattern.
 59. The method of claim 52, wherein the overhangingportion comprises a portion of the second prefabricated sheet thatoverhangs the second backing layer at a first lateral edge of the secondbacking layer.
 60. The method of claim 52, wherein the adhesivecomprises a construction adhesive.
 61. The method of claim 52, whereinthe first backing layer comprises holes between 1/16 inch and 2 inches.